Hair brush and other bristled items, and their methods of manufacture and use

ABSTRACT

A hair brush is disclosed herein that includes a handle, a base and a plurality of bristles, wherein the base and the plurality of bristles are one single continuous component. A method of producing a sanitary hair brush comprises: a) providing at least one curable material, b) injection molding the at least one material into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component. Another method of producing a sanitary bristled item includes: a) providing at least two curable materials, wherein a first curable material is chemically different from a second curable material, b) injection molding the at least two materials separately into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component, wherein the first curable material is used to form the plurality of bristles and the second curable material is used to form the handle and the base. Bristled items produced from these methods are also contemplated.

This United States Continuation in Part Application claims priority to U.S. Utility application Ser. No. 12/580,180 entitled “Hair Brush” and filed on Oct. 15, 2009, which is commonly-owned and incorporated by reference in its entirety.

FIELD OF THE SUBJECT MATTER

The field of the subject matter is a hair brush or any item that comprises bristles that is designed such that it does not collect dead skin cells, hair products, water, bacteria, and/or dirt allowing it to be easily cleaned, effectively disinfected and kept sanitary after each use.

BACKGROUND

There are as many different hair brushes as there are hairs on a head, and yet, most hair brushes are designed the same way. Hair brushes have three primary parts: the handle, the base and a plurality of bristles arranged on the base. The bristles are usually made out of a material that is durable and suitable to interact with hair, while the base is usually made out of material that is durable, suitable to hold the bristles and, in some instances, able to perform other tasks—such as heating hair in order to straighten it or curl it, depending on the shape of the base.

The problem with most brushes is substantially related to the way that they are designed and assembled. Each bristle is stuck separately into the base, such that there is at the very least a plurality of exposed holes in the base where the bristles fit. Given that the bristles may not completely fill the holes, there are some areas of the base where dead skin cells, hair products, water, bacteria, and/or dirt can collect. When all of this unwanted material collects on the base, the exposed holes can fill up with a resin-like mix of materials that cannot be easily removed with routine cleaning. In other brush designs, the base has tracks where lines of bristles fit. Again, in these designs, mixtures of unwanted materials settle in the track areas making it difficult to easily clean and properly disinfect.

U.S. Pat. No. 2,795,807 issued to Salvy discloses a hair brush where there is a base that runs the full length of the brush where the handle and the base are one unit. A detachable and flexible sheet that includes the bristles that are fixed to the sheet slide on to the base frame utilizing a series of cooperating grooves. There are some significant problems with this design. First, the cooperating grooves provide a lengthy area where dirt, water and bacteria can collect. In addition, there is a space between the base and the sheet where water and bacteria can collect and mold can develop, if the brush is not properly and regularly cleaned. Finally, the brush portion cannot be detached from the handle, in order to use the brush as a smaller piece. The handle and the base are one unit, and if the bristles sheet is removed from the brush, it is flexible and unusable on its own.

U.S. Pat. No. 2,851,713 issued to Tupper discloses a combination soap container and scrubber. This design suffers from many of the same problems as the Salvy reference. First, the bristles are designed on a sheet of material that is designed to be slidably coupled with an open container. This open container can be used to hold a bar of soap. Clearly, dirt, water, soap and bacteria can collect in many of the crevices and coupling areas. In addition, it appears that the soap in Tupper can be used and dispersed in the handle while the brush is in use, which indicates that there may be holes or points of collection of water on the brush/bristles.

U.S. Pat. No. 2,889,567 issued to Solomon discloses a brush as well. Column 2 in Solomon states “the rows 21 and 22 join the head 10 in enlarged portions, as at 21′ and 22′, thus providing a strong mounting on the head and at the same time facilitating free flexure of the bristles in the use of the brush”. (emphasis added) There is no discussion in the patent regarding moulding the bristles as part of the head of the brush as one piece. Another feature of Solomon is that the brush head is hollow and rounded, and it is this hollow in the brush that allows soap, water, dirt and bacteria to collect. In addition, the Solomon reference does not disclose a detachable handle, and given that the Solomon reference teaches a one-piece head and handle configuration—there is no teaching of a removable handle.

It would be ideal to develop a brush design or any item that comprises bristles that would be easy to manufacture, easy to use and most importantly, easy to clean, properly disinfect and keep sanitary.

SUMMARY

A sanitary hair brush is disclosed herein that includes a handle, a base and a plurality of bristles, wherein the base and the handle comprise a first curable material and the plurality of bristles comprise a second curable material, and wherein the base and the plurality of bristles are one single continuous component.

A method of producing a sanitary hair brush comprises: a) providing at least two curable materials, wherein a first curable material is chemically different from a second curable material, and b) injection molding the at least two materials separately into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component, wherein the first curable material is used to form the plurality of bristles and the second curable material is used to form the handle and the base.

Another method of producing a sanitary bristled item includes: a) providing at least two curable materials, wherein a first curable material is chemically different from a second curable material, and b) injection molding the at least two materials separately into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component, wherein the first curable material is used to form the plurality of bristles and the second curable material is used to form the handle and the base.

Sanitary bristled items produced from these methods are also contemplated.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1A and 1B show an upper and a side view of a contemplated hair brush, wherein the hair brush has been molded into one single continuous piece of material. In these Figures, the hair brush base comprises one material that is hard or solid and the bristles comprise another material that is flexible and allows bending.

FIGS. 2A and 2B show an upper and a side view of a contemplated hair brush, wherein the hair brush base and plurality of bristles have been injection molded or otherwise molded into one single continuous piece of material and the handle is designed to be detachable. In these Figures, the hair brush base comprises one material that is hard or solid and the bristles comprise another material that is flexible and allows bending.

In FIG. 3, the broom 310 that comprises a first material, a handle 320 and a plurality of bristles 330 that comprises a second material, wherein the first material and the second material are different from one another.

A method 400 of producing a sanitary hair brush is shown in FIG. 4 and comprises: a) providing at least two curable materials 410, b) injection molding the at least two materials separately into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component 420.

Another method 500 of producing a sanitary bristled item is shown in FIG. 5 and comprises: a) providing 510 at least two curable materials, wherein a first curable material is chemically different from a second curable material, b) injection molding 520 the at least two materials separately into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component, wherein the first curable material is used to form the plurality of bristles and the second curable material is used to form the handle and the base.

DETAILED DESCRIPTION

A brush design has been developed that is easy to manufacture, easy to use and most importantly, easy to clean, properly disinfect and keep sanitary. A hair brush or any item that comprises bristles is disclosed herein that includes a handle, a base and a plurality of bristles, wherein the base and the plurality of bristles are one single component. The phrase “one single component” is used herein to mean that they are one single piece of material that comprises at least two different chemical or polymer components, as will be described herein. The phrase “one single component” means that the base and the plurality of bristles are not designed to be separated from one another. It should also be understood that the term “base” means the hard or solid portion of the brush, such as the head of the brush that is coupled to the bristles. The term “base” does not mean simply a base for the bristles, wherein the base is then further coupled to the head of a brush that is not the handle.

FIGS. 1A and 1B show an upper 100 and a side 105 view of a contemplated hair brush, wherein the hair brush has been molded into one single continuous piece of material. It should be understood that the molding of the brush may be by injection molding. It is contemplated that the material used to make the base and handle of the brush is solid or hard and is different from that material used to make the bristles, which will be flexible. Therefore, the two different materials will be injection molded or molded together to form the one single continuous piece of material. In FIG. 1A, the upper view 100 of the brush can be seen that comprises a base 110 that comprises a first material, a handle 120 and a plurality of bristles 130 that comprises a second material, wherein the first material and the second material are different from one another. This is understood and shown in the figures, in that the plurality of bristles 130 have flexible movement 140 with respect to the solid base 110; however the brush is one single component, in that the bristles are injection molded or otherwise formed as a fully integrated and physically coupled unit with the base. The bristles are not inserted separately into the base and cannot be removed from the base. FIG. 1B shows the side view 105 of the same brush comprising a base 110, a handle 120 and a plurality of bristles 130.

FIGS. 2A and 2B show an upper 200 and a side view 205 of a contemplated hair brush, wherein the hair brush base or head and plurality of bristles have been molded into one single continuous piece of material and the handle is designed to be detachable. In FIG. 2A, the upper view 200 of the brush can be seen that comprises a base 210, a detachable handle 220 and a plurality of bristles 230, wherein the handle is detachable at point 225 from the base 210. It should be understood that the detachment point 225 is designed such that the base 210 can be used alone and apart from the handle 220, while allowing for both pieces to be easily cleaned. However, the base cannot be separated from the bristles. Also, the detachment point 225 is not designed such that it will act as a collection point for dirt, hair products, dead skin cells, water and bacteria after a simple cleaning. In FIG. 2B, the side view 205 of the brush can be seen that comprises a base 210, a detachable handle 220 and a plurality of bristles 230, wherein the handle is detachable at point 225 from the base 210.

In FIG. 2A the upper view 200 of the brush can be seen that comprises a base 210 that comprises a first material, a handle 220 and a plurality of bristles 230 that comprises a second material, wherein the first material and the second material are different from one another. This is understood and shown in the figures, in that the plurality of bristles 230 have flexible movement 240 with respect to the solid base 210; however the brush head 250 (the combination of the base 210 and the plurality of bristles 230) is one single component, in that the bristles are injection molded or otherwise formed as a fully integrated and physically coupled unit with the base. The bristles are not inserted separately into the base and cannot be removed from the base.

FIG. 3 shows a side 305 view of a contemplated sanitary bristled item, which in this case is a broom with a full length handle, wherein the broom has been molded into one single continuous piece of material. It should be understood that the molding of the broom may be by injection molding. It is contemplated that the material used to make the base and handle of the broom is solid or hard and is different from that material used to make the bristles, which will be flexible. Therefore, the two different materials will be injection molded or molded together to form the one single continuous piece of material. In FIG. 3, the broom 310 that comprises a first material, a handle 320 and a plurality of bristles 330 that comprises a second material, wherein the first material and the second material are different from one another. This is understood and shown in the figures, in that the plurality of bristles 330 have flexible movement 340 with respect to the solid base 310; however the broom is one single component, in that the bristles are injection molded or otherwise formed as a fully integrated and physically coupled unit with the base. The bristles are not inserted separately into the base and cannot be removed from the base. In some embodiments, contemplated brooms may have shorter handles, so that the broom can be used for quick clean-ups in small places.

A contemplated brush design or other bristled item is molded or otherwise produced in such a way as to have the base and the plurality of bristles be one continuous piece of material. In some embodiments, the one continuous piece of material is designed and produced such that it has no divits, depressions, grooves, holes and/or other spots on the surface of the base where unwanted matter can collect. It should be understood that this design can be used in any design that contains or comprises bristles, such as a broom, a pet brush, a scrubber, a sweeper or any other suitable design.

A method 400 of producing a sanitary hair brush is shown in FIG. 4 and comprises: a) providing at least two curable materials 410, b) injection molding the at least two materials separately and/or individually into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component 420. In some embodiments, a curable material may be injection molded in order to form a base-bristle component. In another embodiment, a couple of different materials may be injection molded in order to produce a base-bristle component, wherein the bristles are made from one type of material that transitions into another type of material for the base. So, for example, a material that cures into a flexible, but durable material may be injected first in order to form the bristles, and a material that cures into a harder material may be later infused and injected later into the molding process to form the harder base. As used herein, the term “separately” means that the at least two curable materials are not blended together and then injection molded, but instead are utilized separately wherein each curable material maintains at least about 90% of its chemical properties, and in some embodiments 95% of its chemical properties. It is understood that the at least two curable materials will blend together or merge at some point by definition of the contemplated embodiments, but each material will maintain a sufficient amount of its own chemical properties in order to fulfill its function—to be hard/solid or to be flexible/bending after cure.

Another method 500 of producing a sanitary bristled item is shown in FIG. 5 and comprises: a) providing 510 at least two curable materials, wherein a first curable material is chemically different from a second curable material, b) injection molding 520 the at least two materials separately into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component, wherein the first curable material is used to form the plurality of bristles and the second curable material is used to form the handle and the base. Bristled items, such as long handle brooms, short handle brooms, pet brushes or other bristled items, produced from these methods are also contemplated.

In some embodiments, the handle may be one piece of material, along with the base and the plurality of bristles. In another embodiment, the handle may be removable, in that different handles can be attached to the base-bristles component in order to provide the user with different functionality. For example, a handle may be a traditional plastic handle designed to be rinsed off and reused. Another contemplated handle may be round and covered in a grippable material. Another contemplated handle may be one that contains an inner compartment that can hold a small item, such as a lipstick or a small bottle of hairspray, as long as the inner compartment and handle is designed such that it will not act as a collection point for dirt, hair products, dead skin cells, water and bacteria after a simple cleaning. This type of handle can be used with the base-bristle component when the user is traveling or going out for the evening.

A contemplated handle may be cylindrical or tubular (including oval or elliptical), triangular, square, polygonal, wider at one end than the other, and can be designed in any shape allowing a person to grab and utilize the hairbrush. For example, the hairbrush handle can be cylindrical with depressions large enough to accommodate the width of a person's fingers or the handle can have a flat, rectangular body. A contemplated handle may have a continuously curved convex region and radially smaller end regions. A contemplated handle may comprise and/or be covered with a grippable material, as long as the grippable material does not collect or allow for the collection of dirt, hair products, dead skin cells, water and bacteria after a simple cleaning.

In a contemplated embodiment, the hair brush may comprise the same material for all of the components, including the handle, the base and the plurality of bristles, but in most embodiments, the material used for the handle and the base is going to be hard or solid and the material used for the bristles is going to be flexible and malleable. In the latter case, it should be understood that the two different materials are injection molded or otherwise molded, so that they keep their contemplated form—either solid/hard or malleable. A contemplated material may comprise plastic, polymer material, composite material, graphite material, a metal-based material, a sustainable or “green” material, such as bamboo or a combination thereof.

A contemplated hair brush can be manufactured with different combinations of materials, lengths, diameters and in different colors. The handle segment can be manufactured in any desired shape and does not necessarily have to match the shape of the base of the hair brush. For example, a contemplated handle can have a circular cross-sectional shape, an elliptical cross-sectional shape, a triangular cross-sectional shape, a square cross-sectional shape, a trapezoidal cross-sectional shape or a polygonal cross-sectional shape.

Thus, specific embodiments and applications of a novel and sanitary hair brush and other bristled items have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure herein. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. 

I claim:
 1. A sanitary hair brush, comprising: a handle, a base, and a plurality of bristles, wherein the base and the handle comprise a first curable material and the plurality of bristles comprise a second curable material, and wherein the base and the plurality of bristles are one single continuous component.
 2. The hair brush of claim 1, wherein the handle is one continuous component with the base and the plurality of bristles.
 3. The hair brush of claim 1, wherein the handle is detachable from the continuous component.
 4. The hair brush of claim 1, wherein the handle, the base and the plurality of bristles comprise different materials, wherein the handle and the base are curable into a hard material and the plurality of bristles are curable into a flexible material.
 5. The hair brush of claim 1, wherein the first curable material and the second curable material are chemically different from one another.
 6. The hair brush of claim 1, wherein the handle is a plastic handle designed to be rinsed off and reused.
 7. The hair brush of claim 1, wherein the handle is round and comprises a grippable material.
 8. The hair brush of claim 1, wherein the handle comprises an inner compartment that can hold a small item.
 9. The hair brush of claim 8, wherein the small item comprises a lipstick or a small bottle of hairspray.
 10. The hair brush of claim 1, wherein the brush is formed by injection molding.
 11. The hair brush of one of claim 4 or 5, wherein the material comprises plastic, polymer material, composite material, graphite material, metal-based material or a combination thereof.
 12. A method of producing a sanitary hair brush comprising: providing at least two curable materials, wherein a first curable material is chemically different from a second curable material, and injection molding the at least two materials separately into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component, wherein the first curable material is used to form the plurality of bristles and the second curable material is used to form the handle and the base.
 13. A method of producing a sanitary bristled item, comprising: providing at least two curable materials, wherein a first curable material is chemically different from a second curable material, injection molding the at least two materials into a mold in order to produce a base, a handle, a plurality of bristles or a combination thereof as one single continuous component, wherein the first curable material is used to form the plurality of bristles and the second curable material is used to form the handle and the base.
 14. A sanitary bristled item produced from the method of claim
 13. 